Battery Pack Thermal Insulator with Segmented Elastic Spring
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Solution Overview
Problem
Existing thermal regulation devices for motor vehicle battery packs are bulky, heavy, and inefficient in heat exchange, with issues of non-homogeneous force distribution and risk of corrosion between metal elements, leading to suboptimal battery performance and increased manufacturing costs.
Innovation Solution
A thermal regulation device featuring a molded plastic insulator with elastic hooks for each heat exchanger tube, combined with a cut and bent sheet metal spring part, providing improved contact and insulation while minimizing material usage and facilitating assembly without adhesives.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single-piece spring is used for all tubes of the heat exchanger, then the contact between tubes and battery is improved, but the device becomes bulky and heavier
Solution Approach 1:
The single-piece spring is divided into multiple individual springs, each associated with a specific tube of the heat exchanger. This segmentation reduces the overall weight and bulk of the elastic element while maintaining the contact function for each tube independently, directly resolving the contradiction between reliability of contact and weight of the battery pack.
2Ease of manufacture
If a single-piece spring is used for all tubes, then assembly is simplified, but force distribution becomes non-homogeneous and cannot accommodate tube torsion
Solution Approach 1:
By providing one spring per tube rather than a single spring for all tubes, each spring can independently apply force to its associated tube, ensuring homogeneous force distribution. This segmentation also allows each spring to accommodate torsion of its specific tube without affecting other tubes, resolving the force distribution issue while maintaining assembly simplicity through modular repetition.
Solution Approach 2:
Each spring is locally optimized for its specific tube, allowing the elastic element to adapt to local variations in tube position and orientation. This local quality approach ensures that each tube receives appropriate force and can accommodate its specific torsion requirements, improving overall force distribution homogeneity.
3Reliability
If the spring is connected directly to the battery, then contact is ensured, but battery replacement becomes difficult
Solution Approach 1:
The insulator is introduced as an intermediary element between the spring and the heat exchanger tube. This insulator facilitates easy removal and installation of the spring without direct connection to the battery, enabling simple battery replacement while maintaining reliable contact through the insulator's elastic properties. The insulator acts as a mediator that decouples the spring from direct battery attachment.
4Strength
If metal elements are used throughout the battery pack, then structural strength is maintained, but corrosion risk and heat loss increase
Solution Approach 1:
The insulator is made of composite material combining elastic properties with thermal and electrical insulation characteristics. This composite material replaces direct metal-to-metal contact, eliminating corrosion risk while maintaining structural strength through the elastic element's mechanical properties and preserving heat exchange efficiency by reducing unwanted thermal losses to the battery casing.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration enhances thermal and electrical insulation, reduces weight and manufacturing costs, and ensures efficient heat exchange between the battery and heat exchanger, while maintaining reliable contact and preventing corrosion.
Implementation Method 1
an insulator is interposed between the elastic element and the heat exchanger, the insulator being made in the form of a molded plastic part
Implementation Method 2
ensuring good thermal and electrical insulation of the battery
Implementation Method 3
at least one elastic element arranged at the bottom of the housing in order to hold the heat exchanger against the battery
Implementation Method 4
The heat transfer fluid can thus absorb the heat emitted by each battery in order to cool them or, depending on the needs, it can provide it with heat
Implementation Method 5
improve the heat exchange between the battery and the heat exchanger
Data Source
Figure 1~3b
Figure 4~6
Figure 7~9
AI summary
The invention relates to a device for the thermal regulation of a motor vehicle battery pack (1) comprising at least one battery (5) contained in a housing (3), the thermal regulation device comprising: at least one heat exchanger (9) in contact with the battery (5), at least one elastic element (15) arranged in the bottom (14) of the housing (3) so as to hold the heat exchanger (9) against the battery (5). An insulator (13) is interposed between the elastic element (15) and the heat exchanger (9).